Toughened bond layer and method of production

Abstract

According to one embodiment of this disclosure, a coating includes a plurality of elongated reinforcing materials. The coating includes a bond coat in which a first portion of a first elongated reinforcing material is embedded. The coating further includes a ceramic coat adjacent the bond coat in which a second portion of the first elongated reinforcing material is embedded.

1 . A coating comprising:
 a plurality of elongated reinforcing materials;   a bond coat, wherein a first portion of a first elongated reinforcing material is embedded therein; and   a ceramic coat proximate to the bond coat, wherein a second portion of the first elongated reinforcing material is embedded within the ceramic coat.   
     
     
         2 . The coating of  claim 1 , wherein the ceramic coat comprises:
 an oxide layer wherein a third portion of the first elongated reinforcing material is embedded in the oxide layer.   
     
     
         3 . The coating of  claim 1 , wherein the bond coat includes an MCrAlY alloy, wherein M is selected from the group consisting of: nickel, cobalt, and combinations thereof and Cr is chromium, Al is aluminum, and Y is yttrium. 
     
     
         4 . The coating of  claim 1 , wherein the first portion of the first elongated reinforcing material and a first portion of a second elongated reinforcing material face substantially the same direction. 
     
     
         5 . The coating of  claim 1 , wherein the first portion of the first elongated reinforcing material and a first portion of a second elongated ceramic material face substantially different directions. 
     
     
         6 . The coating of  claim 1 , wherein a length to diameter ratio of each of the plurality of elongated reinforcing materials ranges from about 3:1 to about 20:1. 
     
     
         7 . The coating of  claim 1 , wherein the first elongated reinforcing material and a second elongated reinforcing material are spaced between about 10 microns to about 100 microns apart in the coating. 
     
     
         8 . The coating of  claim 1 , wherein the component is a component of a gas turbine engine. 
     
     
         9 . The coating of  claim 2 , wherein the oxide layer is a thermally grown oxide layer. 
     
     
         10 . The coating of  claim 1 , wherein the elongated reinforcing materials comprise between about two percent and about twenty percent of the total volume of the coating. 
     
     
         11 . The coating of  claim 1 , wherein the ceramic coat is a thermal barrier coating or an environmental barrier coating. 
     
     
         12 . The coating of  claim 1 , wherein at least one of the elongated reinforcing materials is a whisker, fiber, or platelet. 
     
     
         13 . The coating of  claim 1 , wherein the elongated reinforcing materials comprise a material selected from the group consisting of: alumina, zirconia, titanium diboride, zirconia diboride, silicon carbide, tungsten, tungsten carbide, boron nitride, silicon nitride, and combinations thereof. 
     
     
         14 . A method of coating a component comprising the steps of:
 depositing a bond coat on an outer surface of the component, wherein the bond coat extends from an inner surface bonded to the outer surface of the component to an outer surface, the inner surface and the outer surface of the bond coat defining a first thickness of the bond coat and comprises a plurality of elongated reinforcing materials;   removing a portion of the bond coat so that a first portion of a first elongated reinforcing material is embedded within the bond coat and a second portion of the elongated reinforcing material protrudes from the outer surface of the bond coat; and   depositing a ceramic coat on the outer surface of the bond coat and the second portion of the elongated reinforcing material, so that the second portion of the first elongated reinforcing material is embedded within the ceramic coat.   
     
     
         15 . The method of  claim 14 , wherein the first portion of the first elongated reinforcing material protrudes from the outer surface of the bond coat between about 1 micron and about 10 microns. 
     
     
         16 . The method of  claim 14 , wherein the step of removing the portion of the bond coat is performed using a process selected from the group consisting of: chemical etching or plasma etching, and combinations thereof. 
     
     
         17 . The method of  claim 14 , wherein the step of depositing a bond coat on the outer surface of the component is performed using a process selected from the group consisting of: low pressure plasma spray, electron beam physical vapor deposition, electron beam directed vapor deposition, high velocity air fuel deposition, high velocity oxygen fuel deposition, electrophoretic deposition, slurry deposition and combinations thereof. 
     
     
         18 . The method of  claim 14 , and further comprising:
 forming an oxide layer between the bond coat and the ceramic coat so that a third portion of the first elongated reinforcing material is embedded in the oxide layer.   
     
     
         19 . The method of  claim 14 , and further comprising:
 heat treating the bond coat.   
     
     
         20 . The method of  claim 14 , wherein the ceramic coat is deposited on the bond coat using a process selected from the group consisting of: plasma spray, electron beam, high velocity air fuel deposition, high velocity oxygen fuel deposition, electron beam physical vapor deposition, cathodic arc, and combinations thereof.